Rigid polyurethane (PU) foams are everywhere: they keep our homes warm and our refrigerators cool. Yet, until now, their end-of-life options have been limited to landfill or incineration — wasting valuable raw materials and contributing to climate burdens.
The European research project CIRCULAR FOAM – Systemic Expansion of Territorial Circular Ecosystems for End-of-Life Foam set out to change that. Between October 2021 and September 2025, more than 20 partners from eight European countries collaborated under the coordination of Covestro Deutschland AG. Funded by the EU’s Horizon 2020 programme, the project connected chemical and waste industries, universities, research institutes, and public authorities.
From Waste to Resource
The core question: How can PU rigid foams from construction sites and old appliances be recovered and recycled? The project developed promising answers. With smart pyrolysis, researchers have succeeded in extracting key substances, such as amines, which can then be reused in refrigerators as high-quality alternatives to fossil-based materials. This proves that a closed loop for PU foams is technically feasible.
Digital Tools for Transparency
Equally important were advances in digitalisation. The project created digital product passports to track material composition along the entire value chain, while safeguarding sensitive company data. Tested in practice, these passports showed clear benefits for collection, sorting, and recycling.
Regional Pilots, European Impact
CIRCULAR FOAM also worked in three model regions — North Rhine-Westphalia, Silesia, and Amsterdam — each at a different stage of transformation. By bringing together industry, research, and public authorities, the project developed flexible strategies for a regional circular economy that can be scaled up to other European regions.
Environmental and Economic Benefits
Life cycle assessments confirmed the potential: the new system design can significantly cut CO₂ emissions and reduce disposal costs. By optimising the number, size, and location of recycling plants, the project also demonstrated how to build an economically viable recycling infrastructure.
A Systemic Breakthrough
What makes CIRCULAR FOAM stand out is its systemic approach. From waste collection and chemical recycling to digital solutions and regional cooperation, the project linked all the pieces of the puzzle. The result: a blueprint for turning a problematic waste stream into a sustainable resource. For more details, in-depth materials, and five short films on the project results, visit www.circular-foam.eu.
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 101036854.